Process of and apparatus for manufacturing metallic alloys



no.- 623,692. U I Patented Apr. 25, I899.

v I c-. AGKEB. I PROCESS OF AND APPARATUS FUR MANUFACTURING METALLIC ALLUYSL (Lpplieationflled Mar. 5, 1898.)

(No Model.) 2 Sheets-Sheet l.-

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WITNESSES: INVENTOR Mfflwu/ BY Midi HKATTORNEY m: Nuams pzrzas c0, PHQTO LX TNO., WASHINGTON, n. c.

' Patented Apr. 25. I899.

c. E. ACKER. PROCESS OF AND APPARATUS FOR MANUFACTURING METALLIC ALLOYS.

(Application filed Mar. 5, 1898.)

(No Modal.)

2 shear-sheet 2.

- facture of metallic alloys.

' a citizen of the United States, residing at East 'Erange, in the county of Essex, State of New 'diumto electrolysis while superimposed chanically circulating this alloy, so that the llNr'rnn rates CHARLES ERNEST AOKER, OF

LATENT FFTCE.

EAST ORANGE, NETV JERSEY.

PROCESS OF AND APPARATUS FOR MANUFACTURING METALLIC ALLOYS.

I SPECIFICATION forming part of Letters Patent No. 623,692, dated April 25, 1899.

Serial No. 672,724r (N0 model.)

To all whom it may concern.-

Be it known that I, CHARLES ERNEST AoKER,

iersey, have invented a new and useful Imrovement in Electrolysis, of which the folwing is a specification.

My invention consists of an improved electrolytic process and apparatus for the manu- Briefly stated, the process consists in submitting a fused saltc. g., the chlorid of soupon a molten mass of the heavy metal 6. g. lead'constituting the cathode, and thereby forming an alloy of sodium and lead, in melighter and richer portion formed on the surface will be removed into and accumulate in an adjoining chamber, whence it will overflow or from which it may be periodically tapped, or where the contained sodium may be removed by vaporization from the free and exposed surface of the alloy and separately collected or removed by the action of steam, air, or any other reagent, or the alloy and the sodium may be simultaneously produced and separately collected.

In the process here described continuity, regularity, and uniformity of action are secured and rich alloys produced by providing a system of circulation of the metal of the cathode, which is, in eifect, a continuous skimming operation, whereby the lighter surface alloy thus secured is drawn into an adjoining chamber, where it accumulates by reason of ifts lower specific gravity at and near the surace.

In the accompanying drawings I have shown one form of furnace which may be used in carrying out my process.

Figure 1 is a vertical section. Fig. 2 is a section along line 0 o of Fig. 1. Fig. 3 is an enlarged detail view of the screw in elevation; and Fig. 4 is a plan view of the screw, partly in section, on the same scale as Fig. 3.

Similar letters and figures of reference refer to corresponding parts in the several views of the drawings.

K is a cast-iron hearth supporting, by suitable lugs, the cast-iron pan or partition L and wrought-iron cylindrical chamber G. Upon the rim of the hearth is the magnesia lining J, and surrounding the chamber is a magnesia cylinder H. A tile cover I rests on the magnesia cylinder and lining and is provided with openings for a suitable number of anodes, as at R, and openings for feeding salt, as at V, side walls A being provided on the saltreceptacle. Through the center of the hearth a tube 0 projects upwardly to a point above the intended level of alloy in the chamber, and surrounding this tube in the furnace is an inverted cup 4, carrying at the bottom a screw M, the blades of which are designed to force the liquid outwardly and away from the axis. The cup, with the screw, is mounted rigidly on the shaft N, supported and having its bearings below the furnace.

Suitable pipes for feeding lead, collecting the products, &c., are provided as described later, and the whole is suitably incased in brickwork or equivalent heat-insulating material. In starting the furnace sufficient molten lead is run in to seal the chamber G and cover the pan or partition L. The anodes having been previously placed in position with one of themlowered into the molten lead, the full current is turned on, passing down through the one anode and through the lead to the exterior of the furnace by any suitable connection, as at Z. Dry salt is quickly fed in on top of the lead and around the anodes. The anode carrying the full current is then raised slightly above the lead, as indicated by the voltmeter, thereby forming an arc. The surrounding salt quickly melts and thereafter conducts the current. The melt soon extends to the anodes on either side until the entire charge is fluid, and the furnace works steadily at nearly the normal voltage. The salt is decomposed by the current, chlorin being liberated at the anodes and passing off through channel and pipe U to the point where it is utilized. The sodium is liberated at the cathode-surface, where it forms an alloy. The screw M is set in motion and by a comparatively slow but positive action pulls the surface alloy continuously down between the pan or partition and chamber, when the lighter portion rises to the surface in the chamber and the heavier alloy sinks and follows the pull of the screw and passes up under the pan or partition to the surface, where it comes in contact with the molten electrolyte, becomes the true cathode, and takes up the liberated sodium as it passes over the pan toward the chamber. The screw is turned fast enough to produce a definite movement toward and into the chamber of the shallow body of alloy in contact with the electrolyte. The forced circulation of this surface alloy continuously removes that part which is richest in sodium away from the molten salt. Salt is fed at regular intervals until the desired working depth is obtained and to replace that decomposed. The alloy becoming richer and lighter and more bulky rises in the chamber to a height dependent on the height of the column of salt outside and the relative specific gravityof the alloy and the salt. An overflow-pipe which projects npwardlyin the chamber to a point previously determined or which runs from the exterior of the furnace thereto may be used whenever the alloy is to be removed bodily. Down it the alloy will overflow almost continuously of nearly uniform richness, provided appropriate charges of lead and salt are fed at frequent and regular intervals. Lead is introduced in small charges, either in the molten state or in pigs of uniform weight, at definite intervals into the pipe S, which is sufficiently close to the highly-heated interior of the furnace to insure the fluidity of its contents. The charge therefore enters the furnace from below, the oxid and scum remaining on the surface in the feed-pipe. The salt is heaped up on top of the furnace and surrounding the anodes to a considerable depth, and thus serves to keep in the heat to effect a packing around the anodes by bridging over the small annular spaces surrounding them where they pass through the cover and to utilize what heat would otherwise be lost to thoroughly dry and heat the salt before it is introduced into the furnace. I consider this utilization of the salt for purposes specified as being of great value, dispensing as it does with packings, lutes', &c., besides conserving the heat of the furnace. After the furnace has been in operation several hours and the walls have become thoroughly heated it will thenceforth work at maximum economy and the volt meter-needle will remain stationary as long as the proper operating conditions are fulfilled.

I am unwilling to be confined to the details of the furnace which I have illustrated. Various arrangements of parts other than those illustrated may be used without in any case departing from the essential principle of operation described in the specification namely, the removal of the lighter and richer alloy from the cathode-surface into a cham ber where it is no longer incontact with the molten electrolyte.

\Vhat I claim as new, and desire to secure by Letters Patent, is

1. The process of m aki ng an alloy of a heavy metal such as lead, tin, zinc, &c., with a metal of an alkali or of an alkaline earth, consisting in reducing the heavy metal in a molten state, and employing it as a cathode electrolytically decomposing a fused salt of the metal of an alkali or of an alkaline earth, while superimposed upon the heavy metal, removing the resulting alloy from the region of the electrolyte, subsequently permitting its different portions to stratify, and flowing off the lighter portion from the surface, substantially as specified.

2. The process of making an alloy of a heavy metal such as lead, tin, zinc, &c. ,with a metal of an alkali or of an alkaline earth, consisting in reducing the heavy metal to a molten state, and employing it as a cathode, electrolytically decomposing a fused salt of the metal of an alkali or of an alkaline earth while superimposed upon a heavy metal, removing the resulting alloy from the region of the electrolyte, subsequently permitting its different portions to stratify and returning the heavier portion to the point where it takes up the lighter metal, substantially as specified.

3. The process of making an alloy of a heavy metal such as lead, tin, zinc, &c., with a metal of an alkali or of an alkaline earth, consisting in reducing the heavy metal to a molten state and employing it as a cathode, electrolytically decomposing a fused salt of the metal of an alkali or of an alkaline earth while superimposed upon the heavy metal and resulting alloy; circulating the cathode metal in a stream past the anode or anodes into another chamber having a non-oxidizing atmosphere; allowing it to stratify there; and in removing from said chamber the upper portion of the alloy, substantially as specified.

4. The process of making an alloy of a heavy metal such as lead, tin, zinc, &c. with a metal of an alkali or of an alkaline earth, consisting in reducing the heavy metal to a molten state and employing it as a cathode, electrolytically decomposing a fused salt of the metal of an alkali or of an alkaline earth while superimposed upon the heavy metal, circulating the cathode metalin a stream past the anode or anodes into another chamber having a non-oxidizing atmosphere; removing a portion of the metal from near the bottom of said chamber and causing it to again circulate in a shallow stream past the anode or anodes, substantially as specified.

5. In an apparatus for electrolytically decomposing fused salts, the combination of a covering for said apparatus provided with an opening receiving an anode, a body of salt resting on said covering and partly closing said opening, and a body of fusible metal constituting a cathode, substantially as specified.

6. In an apparatus for the electrolytic manufacture of an alloy from a heavy metal such as lead, tin, zinc, 85c. with a metal of an alkali or of an alkaline earth, the combination with an anode, of a cathode composed of the heavy metal, a chamber having a non-oxidizing atmosphere and with which the metal of the ICC cathode is in fluid communication said chamber being sealed against access of the electrolyte and into which chamber the alloy rises, means for automatically removing the alloy from the chamber when it exceeds the desired level, and a circulating device arranged to withdraw molten metal from the lower portion of said chamber and to cause a shallow stream of the molten metal to flow transversely below the electrolyte, substantially as specified.

7. In an apparatus for the electrolytic manufacture of an alloy from a heavy metal such as lead, tin, zinc, &c., with a metal of an alkali or of an alkaline earth, the combination with an anode of a cathode composed of the heavy metal, a chamber with which the oathode metal is in fluid communication and which is sealed against access of the electrolyte, a circulating device, and a pan or partition immersed in the cathode metal slightly below the true cathode-surface, and having an extension or continuation toward the circulating device, openings or channels being provided in or partly formed by saidpan or partition and its extension, whereby the molten metal my flow underneath and over the same, substantially as specified.

8. The process of making an alloy of aheavy metal such as lead, tin, zinc, &c., with ametal of an alkali or of an alkaline earth, consisting in reducing the heavy metal to a molten state and employing it as a cathode; in electrolytically decomposing a fused salt of the metal of an alkali or of an alkaline earth while superimposed upon the heavy metal; in circulating the cathode metal in a shallow stream pastan anode or anodes into a separate chamber having a non-oxidizing atmosphere; in supplying the heavy metal to the lower portion of said chamber and thereby displacing a portion of the alloy; in removing another portion of the alloy from the lower portion of said chamber; and in causing the latter to circulate in a shallow stream past an anode or anodes; the supply of heavy metal and salt and the circulation being so regulated as to maintain an approximately constant distance between the anode or anodes and the cathode, substantially as speci- 5o It is hereby certified that in Letters Patent No. 623,692, granted April 25, 1899,

2 upon the application of Charles Ernest Acker, of East Orange, New Jersey, for an improvement in Processes of and Apparatus for Manufacturing Metallic Alloys errors 1 appear in the printed specification requiring correction as follows: On page 2, lines 9899, the Words and resulting alloy should be stricken out and inserted after the 1 Won metal, line 99, same page, as now numbered, and line 27, page 3, the Word 1 my should read may; and that the said Letters Patent should be read With these corrections therein that the same may conform to the record of the case in the Patent 1 Ofiice.

Countersigned Corrections in Letters Patent No. 623,692.

Signed, countersigned, and sealed this 2d day of May, A. 1)., 1899.

[sEAL] \VEBSTER DAVIS,

Assistant Secretary of the Interior.

C. H. DUELL 7 Commissioner of Patents. 

